Stabilization of fluidized iron synthesis catalyst



Nov. 4; 1952 c. -w.'wA'1'soN STABILIZATION OF FLUIDIZED IRON SYNTHESIS CATALYST Filedoct. 30. 1947 INVENTOR.

C. W WA A TORNEYS' lcontact in the reaction zone.

Patented Nov. 4, 1952 STABILIZATION OF FLUIDIZED IRON SYNTHESIS CATALYST Y Claude W. Watson, Port Arthur, Tex., assigner to The Texas Company, New York, N. Y., a

corporation of Delaware Application October 30, 1947, Serial No. 783,064

(Cl. Bll-449.6)

, Claims. 1

The present invention relates tothe synthesis of hydrocarbons, oxygenated hydrocarbons and the like by the catalytic reduction of carbon oxide with hydrogen, and is more specifically concerned with conducting said reaction through the agency of an active catalyst effective to yield high conversions of reactive feed material into normally liquid hydrocarbons without undesirable catalyst disintegration.

In accordance With the present invention, the synthesis of desired liquid products of reaction is elfected'in the presence of a fiudized ironcontaining catalyst possessing high resistance to subdivision resulting from the chemical action of the gases and vapors with which it comes in To this end, the catalyst is composed of its intimately associated components physically bonded into solid particles of proper size for uidization under the reaction conditions prevailing in the synthesis operation, the components thereof maintaining their physical integrity under reaction conditions at which high yields of predominantly liquid, desired products of reaction are realized.

The invention is particularly applicable to hydrocarbon synthesis `operations wherein the active catalytic component comprises iron and iron-containing compounds effective at tempera- `tures within the range of about 550 to '700 F.,

for example, and preferably under superatmospheric pressure, as for example, 150 to 300 p. s. i.

In the synthesis'of hydrocarbons, the extent of conversion of vthe reactant feed, expressed, for example, as the percentage conversion of the feed carbon monoxide into desired products containingnot less than three carbon atoms in the molecule, has been in the past relatively low. At first this was primarily due to the diiiiculty of removing the exothermic heat at arate at which the necessary narrow optimum range of operating temperature can be sustained. With the advent of the fluid catalyst technique, temperature control was `improved to the extent Where the extent of the reaction could be materially improved. Thus the catalyst, in a state of dense phase iiuidization, may be held substantially at a predetermined temperature level by provision of adequate cooling, surfaces in contact therewith. So also, by adjusting the reaction conditions and particularly the composition of f total feed to the reactor, and by selection of active catalysts, .a substantial approach to theoretical yield was made available.

, l In particular, amaterial improvement in the 'degree of conversion to C3 andhigher hydrocarbons may be realized by recycling normally gaseous products of reaction or selected components thereof. One such method, disclosed in my copending application, Serial Number 630,521, filed November 23, 1945, contemplates maintenance of a relatively high carbon dioxide recycle which suppresses net carbon dioxide formation and induces high yields of desired liquid hydrocarbons with ultimate disposal of the oxygen largely as Water. A'

However, during extended operation under conditions of high conversion, the usual initially reduced catalyst progressively tends tol disintegrate or spall into progressively ner particles. As conversion increases above about on the basis of the carbon monoxide converted into desired liquid products containing at least three carbon atoms, there is a corresponding tendency toward catalyst disintegration, which causes reduction inV density of the fluid catalyst bed and lessened turbulence. These result in decrease in the heat transfer rate desirable for good heat control. More significant, however,v is the fact that the finely divided particles of spalled catalyst are carried out of the reaction zone as lines, requiring the addition of fresh catalyst makeup at an uncconomical rate. In short, under conditions of high yield of desiredV products, the catalyst becomes subdivided to a condition where it can no longer be effectively maintained in dense fluid phase in the reaction zone.

The present invention overcomes this effect by providing a catalyst which vis adapted to conform with equilibrium catalyst chemical composition without physical degeneration and thus may be subjected to continuous use under conditions required for maximum yields without excessive subdivision. To this end, the catalyst is composed of physically bonded, integral solid particles of suitable physical hardness and strength and of proper size for fluidization.

The .catalyst conforming with the equilibrium catalyst chemical composition isformed of the nely divided productsof catalyst disintegration and spalling, recovered from a synthesis operation of the ,above character, carried out under typical reaction conditions, preferably, however, conditions approximating those under which the prepared catalyst is to be employed.

Presumably, the fine particles produced by 3 der reaction conditions, they exhibit a marked compatibility with the reactants such that chemical subdivision is prevented.

Physical bonding of the catalytic ingredients into particles of the indicated composition may be effected by ementing, sintering, or otherwise agglomerating an intimately associated mixture thereof by any suitable means, thereafter comminuting or subdividing the agglomerated mass, and then grading to the required mesh size. Alternatively, the mixture may bdilectly bonded into particles of the required size, for example, by pelleting.

Agglomeration of the mixed powder into asolid mass may be easily eecte'd through the agency of a suitable refractory cement, such, for example, as any of the typicall calcium aluminate hydraulic cements. Any other cementing material substantially free from substantial impairing effect upon the synthesis reaction and resistant to the temperatures employed may, however, be substituted. silicates such as yzirconium silicate provide a somewhat less effective binding agent.

Alternatively, integration of the powder may be accomplished by baking at an elevated temperature, preferably after compacting or agglomerating it with an adherent material such as asphalt dissolved in naphtha. It will be understood that compacting is followed by drying and baking, preferably'under'a vacuum or under a neutral atmosphere and at temperatures such that the mass possesses the necessary hardness and strength. Similarly, in the preparation of a fired, sintered or calcined product, the asphalt binder may be substituted by an aqueous suspension or slurry of a refractory material such as zirconia or magnesia, produced by prolonged grinding in a bali mili or the like. It wiii'be understood that the slurry is admixed with the powder just suiiicient proportion to permit ready compacting or ramming into a highly compacted mass suitable for drying and firing.

The final integratedV composition may be sized and graded by a combination of grinding followed by screening or any other conventional separation. The product thereby produced possesses a 'physical strength and resistance to abrasion dependantV upon the method'of integration employed. Where the aforementioned calcium aluminate cement is employed in a typically effective proportion such as one volume Vof cement foreach four volumes ofcatalyst powder, thereafter permitted to set and then dried, the resulting composition possesses physical resistance to abrasion ideal for iluid catalytic conversion processes, )and moreover, being an equilibrium catalyst, is not subject to subdivision by chemical attack.

The specific size of the ultimate particles prepared will vary somewhat, depending upon the specific reaction conditions and particularly the rate of` gas flow which will be encountered. Normally, however, the particle size will range between about 60 and.400 mesh, usually finer than:

about 100 mesh and-larger than about 325 mesh. I In use, the catalyst is disposed within a reaction zone as a dense phase fluid mass contacting adequate cooling surfaces supplied internally with a coolant such as water maintained atappropriate temperature. The upilow of gaseous reactants may be' relied upon to maintain the particles in a uniform state of dense fluidization, although mechanical adjuncts may be also employed. As above indicated, the` reactionzoneis held under reaction conditions, as for example. at a temperature of about 600 F. and elevated pressure. The efliuent from the reactor is withdrawn from contact with the catalyst at the upper portion of the reaction zone and subjected to condensation and separation of the normally liquid constituents, after which the normally gaseous constituents are recycled as desired to the reaction zone inlet.

As intimated above, the surprising resistance of the present catalyst to spalling during prolonged operation'is believed to result from the fact that its composition is substantially in equilibrium with the chemically active agents present in the reaction zone and thus unsusceptible to the disintegrative chemical change which the usual catalysts vpprrrially tend to undergo during operation. In this respect, it is to be particularly contrasted with the commonly proposed method of catalyst preparation wherein an iron compound is reduced to metallic iron and may be subjected to a conditioning. or carbiding treatment, and thereafter undergoessubdivision in a progressive process involving chemical action analogous to surface rusting 0f iron or .Steel eX.- posed to the atmosphere.

In accordance with the present invention, however, the composition comprisesplltituents in a form physically Compatible. with the equilibrium conditions.

The foregoing statement of. theory sllrlderv stood to be presented solelyto facilitate. 0.0111131?.- hension of the invention, and not byway of limitation.

In order to form the present catalyst from an approximately. equilibrium catalyst composition formed underjreaction CQnditions in the synthesis reaction zone, a suitable product4 may be recovered by collecting thdlle. particles which spall or crumble fromthe introfllld Qftlysii 11,1 the course 0f thesynthesis. reaction- '.Ifhus, Whel1 a conventional iron Miron-containing catalyst is used with a high rate oit-recycle. 0.1. normally gaseous products, particularly carbon dioxide, such that substantiallygreater than about '7,0% ofA im.V carbon, monoxide fed is. converted i0 C3 and higher products, theillae llOitiQns of the catalyst Which ,Separate and spallfin the form of line narticlesarereadily rgQVgrable from the gasiform product stream, and may thereafter b e formed into particlesor pellets of the desired size in themanner disclosed apoye.

`one arrangement sul le for carrying Qui this process is indicated more Q r less diagrammaiioauy inthe attached iranes wherein the reference nuinerfilV ldesienates a Synthesis rsactor containing, a, fluid' ed mass of"r catalyst Il of about 2,0 0 mesh, for eggalnple, which immerses suitable indirect cooling surfiges-y represented by the exchanger l2. Exchanger. I 2v iS Supplied with coolant inlet pipe I3 andthe circulating coolant is Withdrawn through outlet pinoli as a liquid or vapor.. in. accordance with conventional practiCes. 4

The inletv feed to the,y reactor comprises fresh feed introducedfromanyconvenient source not shown through pipo I6, togetherjwiih' aadiiionai recycle streams Whihwill hereinafter be more fully described. The catalyst bed "Il isV maintained in a good state of "densegphase uidization by aY predetermined vu'pflow of reactants, The products of reaction emerge. from the upper pseudo-liquid surface offthe dense Vfluid phase and pass overhead at I9, through `the.cyclone sepstator l'lil` dgsigpqdtd sep ,te any' entraine@ catalyst particles within the 'range 'of size suitable for yforming' the dense yiiuid phase. These are returned through standpipe 22 and mechanical feeder 23'to the gaseous recyclestream, as will hereinafter b'e more fully disclosed, for reintroduction to the reaction zone.

The more vfinely divided particles of catalyst below that size capable of eiective fiuidization are therefore contained in the gas stream passing out -of cyclone separator 20 through pipe 24. These are lrecovered in a second separator 26.

-The thus recovered iines or dustjpass by way of standpipe 21 toa cementing plant 28, operated to physically bind the powder into solid chunks of -substantialmechanical strength by means of refractory cement in the manner fully'disclos'ed above. The bonded chunks ory pieces thereupon are conveyed by means 29 to a 'dryer 30 where moisture is removed, and thereafter, successively go to a grinder 32 anda screening system 34 from which the particles 'l of the desired catalyst'size are delivered. As indicated above, the product may be injected into the recycleiine or returned to'thereaction zone in any other desired manner. Smaller or larger` sizefparticles separated bythe screening step 34 may be returned by any means not shown tothe cementing plant 28, or may be discarded.

' The gaseous products of reaction from which solidshave been removed'pass from separator 2'6 through outletpipe 36'to condenser 31 and thence to' separator 38, wherethe oil layer is recovered as at 39' and the water layer is discharged at 40.

The normally gaseous products removed overhead at 42 arepreferably recycled to the reactor via pipev 43 at a suitable Yrate to maintain the high vyields of desired liquidproduct mentioned above Any appropriate portion of the gaseous overhead vmay be vented through branch pipe 44. Itis particularly advantageous, as indicated above, te` supplycarbon dioxide to the reaction zone. Accordingly, all or a portion of the normally gaseousproducts'of reaction maybe conveyed bybranch pipe 45 to a gas recovery plant 46,.where,for example, a triethylamine absorption system is employedto separate carbondi-` oxide, andthe recovered carbon dioxide stream passes thereafter to recycle line 43 byway of pipew41. Theresidual separated gases are dis- Chareedihrmlshpive 43- In the system` disclosed, the arrangement of valves'permits the recycle streams to be apportioned or controlled as between direct recycle of normally lgaseous constituents through pipe 43, and "recycle offc'arbon 'dioxide by way of branch pipe' 41." Accordingly, vthe concentration of carbon dioxide, as well as other normally gaseous products, inthe total feed to the reactor may be controlled within Wide limits. It will be apparent' from Athe foregoing vthat the recycle stream picks up the product catalyst Yfrom the grading 'system' 34 and the separated catalyst' from the' standpipe 22 Vand conveys it int'ofthe lower portion of the reactor I0. Any suitable injectors 'or conveying means may be added .as-desired. i i Operating in this way with a substantial recycle ofcarbon dioxide as taught inl my copending'applications, Serial Nos. 626,425and 630,521, the essential bil-product` of the reaction' may comprise-the water vapor released at 40, and when using -a`fresh feed comprising essentially carbonmonoxide and hydrogen, only small proportions off-'u'ndesired gaseous by-products are discharged'th-rough pipe 48:1`

I separators, `filter systems, gas clarifiers or the like. Similarly, integration of the iine powderr into catalyst particles of the desired size may be carried out by any suitable system for particle orpellet formation.

In operation with any typical reducedv iron catalyst initially supplied to the reactor l0, a

substantial rate of recycle to the reactor and a.

total feed containing carbon dioxide in such proportion that 80 or 90'per cent of the carbon monoxide supplied is recovered as desired liquid products, a continual chemical subdivision of the catalyst willensue, resulting ultimately in recovery of substantially all of the catalyst in the form of nes suitable for treatment such that the process of physical bonding into particles of the required size'may be effected.

It is particularly important to note that sepa` ration of the fines occurs readily from iiuid cata-` lyst beds at reactant now rates usually proposed. Thus, in a typical case, fine powder less than about 400'mesh formed by chemical alteration of an ordinary reduced iron catalyst becomes promptly entrained in the eiiiuent product stream and'lmay be readily separated outside the reaction zone. While the particle size of the separated solids may vary somewhat depending on reaction conditions and particularly the velocity of gas now in the reactor, such entrainment in any event aifords a separation of particles too fine for effective dense phase uidization, thus automatically retaining within the reactionzone a catalyst mass effective for contacting` the reactants in the desired dense phase state. So also, the particle size of the-.dense phase within the reaction zone affords a suitable measure or approximation of the particlel size range to` which the physically bonded prepared catalytic particleshould be graded for fluidization.. In general, therefore, the prepared particles will be in range of coarser than about, 400 mesh, with an appropriate increase in size as gas `velocities increase. Likewise, as indicated above, the maximum size which determines the other limit of the particle size range, is that which can be caused to become a part of the turbulent iiuid phase, by the gas now or other uidizing iniiuences encountered in operation.

In accordance with one example, a reaction chamber the same as above is charged with a mass of iron catalyst consisting of iron mill scale of 200 to 300 mesh size containing about 2% alumina (A1203) which has been impregnated with fabout 1% poatassia (KzO) The catalyst bed is` subject to reduction by dry hydrogen at about l000 F. until no further moisture is evolved. Thereafter, the synthesis reaction is carried out with the passage of fresh feed reactant gas comprising essentially hydrogen and carbon monoxide in the ratio of 2:1. The fresh feed gas is supplemented-by a recycle of the normally gaseous products of reaction in a proportion equal to about 2.5 times the rate at which the fresh feed 'gas is supplied, on a standard volume basis; Temperature is maintained at about 625 F. and pressure at about 200 p. s. i. The internal upiiow of total feed gas in the lower portion of the reactor, neglecting the volume occupied by the catalyst particles, amounts to approximatelyzfeet persecond, whereby the catalystis maintained in aA condition of dense fluidization.

Ilneeasi,form reaction, prcductscre Withdrawn from the upper iseudo-liquidY surface. of thecata. lyst. condensed te T? F., and the liquid-constitue ents separated from the residualgases. The residual normally gaseous stream, in excess 4of the recycle isvented.

After a short period of operation,- a substantial quantity of fine particles, smaller than algoutjfil) lyst capacity of the reactor .overa periodof ,about` 200 hours, the proportion of fines included in they stream of the reaction products diminlshestoa negligible factor whichl no longen warrants such treatment.

It is contemplated, as intimated in the above example, that the present catalyst may contain any of the conventional activating or 'promotingl agents such as the oxides of the alkali or alkaline earth metals, titania, Zirconia, alumina and many others which are usually employed in minor` portionsas, for example, from 0.5 to 5%. I prefer, however, to include potassia, usually in the range of about 0.5 to 1.5%, and alumina, usually in the range of about 1.5 to 5%.` TheV potassia, or the otherv ingredients, may be incorporated-in anyY convenient manner as indicated above.

In practicing the present invention, provision is advantageously madeV for effectingl Contact between reactants and the catalyst for a-.contact time and under conditions of good turbulence where the reactants effectively scrub thesurface of. the catalyst. To this end, relatively deep cata-ir lyst beds are to be preferred and high. linear ye.- locity of gas flow, above 1.5, preferably above about twofeet per second, in an upward direction is best. Thus, stagnation of the.` gaseous film on thecatalyst surfaceis avoided, with better'overall. yields. As shown above, however, the rate of gas flow. fixes the necessary range of. catalyst particle sizenecessary to attain good dense `phase.

fluidizaticn with characteristic.- high catalyst turbulence or vibration, efficient surface contact. and high rates ofV heat transfer.

The present invention, while broadly applicaf ble to any typical synthesis gas, particularly vcontemplates the use of a fresh reactant feed con. taining carbon` monoxiderand hydrogen in apro.- portion which approximates that required for exclusive reaction with the production of ole.-V ns and water. Where the feed is essentiallyllyw drogen and carbon` monoxide,.the preferred .profportions are, therefore, about V221., that is, inthe. range of about 1.5:1 toy 2,.5:1.j HoWcYensince/as shownr above, high yields of desired liquid prode ucts result when substantial, prcpcrticnsof car.-` bongmonoxide are included inv thel feed to the re. action zone, the fresh feed as .well as thefrecycle Stream may include substantial,proportions .ci carbon dioxide for consumption; inthe Product of the liquidl hydrocarbons.,

The term physically bonding as used herein mea-ns the integration of masses of `finely divided solidsl too ne for effective. dense phase-ilui'diza: tion into larger particlesy of propensizeior fluidie zation by physical means :exclusiyely without al# rity and resistance to disintegration.

It is to be noted that the terms normally liquidl hydrocarbons or desired products of reaction. are intended to include general hydrocarbons containing at least three carbonA atoms, and incidental oxygenated hydrocarbons which `are liquid under normal conditions, notwithstanding that the lower molecular constituents of this` group may be liquid only as absorbed in higher` hydrocarbons, or as subsequently subjected to polymerizationV or the like.`

While the foregoing invention has beendescribed more specifically in connection with certain preferred embodiments,v it is .to be understood that these are by way ofillustraton and net by way of limitation; and the invention should notbe limited thereto, except as determined by the scope of the following claims.

I claim:

l. In the catalytic synthesis of hydrocarbons, oxygenated hydrocarbons` and mixtures thereof, wherein a synthesis gas comprising hydrogen and carbon monoxide is Acontacted in a reaction vzone with a uidized, solid particle, iron, hydrocarbon synthesis catalyst in a range of particle size Lef fective for iiuidization ,under reaction conditions such .thatA the reactants are Vconverted .into high yields of said productsof reaction with progressive physical disintegration ofthe catalyst under the influence of the chemical conditions .Y existing in the reaction zone, into aproduct substantially finer than the said particle size range, the improvement which comprises recovering the disintegration product of said catalyst, integrating separate masses thereofvv by physically bonding said masses withV added Gementitious material, without alterationin the chemical composition thereof, into particles of a size within said range Yeffective for uidization, said bonded masses disintegration product conforming in chemical composition to the recovered disintegration product and being stabilized against further disintegration, continuing said recovery and physical bonding steps until substantially all the catalyst employed in the reaction is so Vstabilized against further disintegration. and thereafter ceasing said recovery andephysical bonding and ,subjecting said bonded particles to contact with synthesis gas under reaction conditions to form substantial yields of said vproducts of reaction without substantial disintegrationV of said particles. I

2, The method according to claim 1, wherein contact between said lsynthesis lgas and catalyst is effected in the presence of asubstantial portion of carbon dioxide at temperature ranging from about v50G-75D" F. with a contact time such that Vabout percent v.of thecarbon monoxide passed in contact with the catalyst is converted into said products .of reaction. I

3. The method according to claim 1 wherein the saidbonded particles comprise masses of said disintegration product physically bonded. by a cementitious material stable at temperatures in the range of 50G-750 F. f

Il. The method according to claim 1 wherein the said bonded particles comprise masses of said disintegration product physically bonded by a calcium aluminatehydraulic cement...

5. The method according. tccclaivxnsfwfherein the said bonded particles are in a size range of from about 60-400 mesh.

CLAUDE W. WATSON.

REFERENCES CITED Number Name Date 2,017,428 Almquist Oct. 15, 1935 2,038,566 Huettner et al Apr. 28, 1936 Number 10 Name Date Scheineman Dec. 28, 1943 Elian Feb. 13, 1945 Johnson Jan. 29, 1946 Redcay Sept. 3, 1946 Huber, Jr Mar. 11, 1947 Millendorf July A27, 1948 Roberts Feb. 15, 1949 Seguro Aug. 16, 1949 Hemminger Sept. 13, 1949 Krebs June 6, 1950 

1. IN THE CATALYTIC SYNTHESIS OF HYDROCARBONS, OXYGENATED HYDROCARBONS AND MIXTURES THEREOF, WHEREIN A SYNTHESIS GAS COMPRISING IN HYDROGEN AND CARBON MONOXIDE IS CONTACTED IN A REACTION ZONE WITH A FLUIDIZED, SOLID PARTICLE, IRON, HYDROGEN SYNTHESIS CATALYST IN A RANGE OF PARTICLE SIZE EFFECTIVE FOR FLUIDIZATION UNDER REACTIN CONDITIONS SUCH THAT THE REACTANTS ARE CONVERTED INTO HIGH YIELDS OF SAID PRODUCTS OF REACTION WITH PROGRESSIVE PHYSICAL DISINTEGRATION OF THE CATALYST UNDER THE INFLUENCE OF THE CHEMICAL CONDITIONS EXISTING IN THE REACTION ZONE, INTO A PRODUCT SUBSTANTIALLY FINER THAN THE SAID PARTICLE SIZE RANGE, THE IMPROVEMENT WHICH COMPRISES RECOVERING THE DISINTEGRATION PRODUCT OF SAID CATALYST, INTEGRATING SEPARATE MASSES THEREOF BY PHYSICALLY BONDING SAID MASSES WITH ADDED CEMENTITIOUS MATERIAL, WITHOUT ALTERATION IN THE CHEMICAL COMPOSITION THEREOF, INTO PARTICLES OF A SIZE WITHIN SAID RANGE EFFECTIVE FOR FLUIDIZATION, SAID BONDED MASSES DISINTEGRATION PRODUCT CONFORMING IN CHEMICAL COMPOSITION TO THE RECOVERED DISINTEGRATION PRODUCT AND BEING STABILIZED AGAINST FURTHER DISINTEGRATION, CONTINUING SAID RECOVERY AND PHYSICAL BONDING STEPS UNTIL SUBSTANTIALLY ALL THE CATALYST EMPLOYED IN THE REACTION IS SO STABILIZED AGAINST FURTHER DISINTEGRATION, AND THEREAFTER CEASING SAID RECOVERY AND PHYSICAL BONDING AND SUBJECTING SAID BONDED PARTICLES TO CONTACT, WITH SYNTHESIS GAS UNDER REACTION CONDITIONS TO FORM SUBSTANTIAL YIELDS OF SAID PRODUCTS OF REACTION WITHOUT SUBSTANTIAL DISINTEGRATION OF SAID PARTICLES. 